Manufacturing Operations, Project Management,Process Engineering c GMP

AUM

Om Prakash Mahto

B.E. (Chem.) I I T Roorkee,

M. Tech. (Chem.) I I T Kharagpur

********@*****.***

Tel. No. 772-***-****

Resident of – Agra (U P )

Overview

Unit Head

Over 14 Years of Experience as Unit Head / GM/ Sr. G M Operations

Expertise in Manufacturing, Projects & Process Engineering

Chemical, Petro, API Bulk drug, Polymer,

Fine & Agro Chemicals, Speciality Chemicals

Batch & Continuous Reactors DCS based Units

Vision

To increase the investors’ value and maximizing profit by improving the operational efficiencies and maximum utilization of the available resources.

Career objectives

A challenging Management position in a fast paced environment to achieve Organizational goals while allowing my personal growth and career advancement to meet my professional excellence, competencies, capabilities, skills, education & experiences.

Career profile Synopsis

29 years of experience of operation of successfully managing all aspects of a large Continuous Chemical, Petro Chemical, Pharmaceutical API Bulk drug, Polymer, fine Chemical with latest technology with PLC, DCS, SCADA based Process control and leading cross-functional teams on key projects.

Wide experience in operations of petro chemical plant with exothermic reactions, CSTRs, heat recovery systems, continuos distillation recovery units of multi columns, Spray drier, centrifuges, crystalizers, FBD, Coal gasifier, Air dryers, Neutche filters, Ozonators, Grannulaters, VAM, Chillers, Membrane cells Air separation units, MEE Vacuum ejectors, Pusher / basket centrifuge, Carbon filter, Molecular sieve dryer, hydrogenators, chlorinators and other associated plants.

Well versed and basic knowledge of turbine, cooling tower, DM water, RO, UF filters, Boilers, hvac, compressors etc.

Ensuring effective Business Monthly Review meeting ( BMR ) & continuous improvement programme .

Monitoring and control of team consisting mechanical, instrument, electrical, utilities and process .

Ensuring plant continuity, safe operations and leading for debottlenecking and trouble shooting .

Always ensuring Hazop & cost benefit analysis before modifications and documentation of built after implementation.

Ensuring operations to maximize efficiency by cost effectiveness, consumptions & variable costs reductions.

Establishing customer relationships on product quality on behalf of the company.

Adhering optimum operating parameters and implementing CAPA as per requirements.

Responsible for each and every activity of plant including production, QC, QA, Engineering, HR, Liasing with govt. bodies, internal co-ordination, customer and vendor dealing etc.

Leading the entire plant team with lot of initiatives and driven them in line of professionally managed organization.

Setting up of a green field projects with complete systems & processes & running in smooth manner.

Proven hands on skills are Manufacturing Operations, Project Management,Process Engineering c GMP, IMS, Process reengineering and improvement, Basic and detailed Engineering, Technical services, Construction Management, Corporate strategy and development, Strategic planning and management, SAP operation, All types of Audits, Operating & Capital expenses control, Statutory compliance, Continuous improvement, Technology transfer, Cost Control measures, Energy conservation, HR and IR Relationship,Material Resource Planning, Negotiation, Ordering, Procurements, Supply chain management, Forecast, Logistic, Safety etc.

Analysis of root cause during repeatative process problem and proposal for CAPA ..

Planning & implementing the preventive & predictive maintenance of Plant, machines, personnel, equipments for improving the overall reliability, safety & maximum efficiency under safe operating conditions.

Ensuring adherence to highest standards thru’ ISO 9000, 14000, 18000, training, ensuring zero accident, monitoring and control of PCB & CPCB standards.

Area of expertise

Technical : Process design of all basic Chemical process equipments like Heat Exchangers, distillation columns, Dryers, vessels, Evaporators etc., Calculations of mass & Energy balance and all type of process requirements and finally profit & loss of Plant .

Profitability: Responsible for resource optimization Cost control, analyzing MIS & Effective Business Review .

Factory Operations & Maintenance: Ensuring quality norms, production targets, smooth operations, Direct involvement in all Plant activities . Reviewing maintenance schedules, maintaining norms w. r. t .Pollution Control Boards.

Set-up Systems and Processes : Ensuring lay down and adhere to Standard Operating Processes (SOPs) & Process definitions .

Liaison : Handling Expense accounting, All compliances, Liaison with Local Authority, Govt. body like excise, pollution, Labour, Industry Deptt. etc., all negotiations.

Petroleum Processing and testing, Petroleum Projects, Petro Chemicals processing . continuous Fractionating column operatios .

I Project Core Experiences;

Responsible for the Development and implementation of the plant's manufacturing plans, methods, and processes.

With most appropriate and cost-effective methods, processes, tools and systems.

Developing the capital expenditure budget & raises CAPEX as required.

Finalize the selection and installation of Process equipments, machines etc.

Responsible for all aspects of Projects objectives to meet Time & Cost Deadlines.

Developing Project Execution Concept and Master Schedule .

Coordinating with Engg. Depts. & Consultants for Design and timely availability of deliverables.

Man-hour Budgeting & Control .

Establishing Engg. Document List & Procedures for Procurement and Vendor Document reviews.

Managing Site Queries & liaising for obtaining various approvals & clearances.

Reporting with MD/Technical Director on project status.

Maintaining safety norms during project concept and execution.

Providing leadership to the project team includes engineering, procurement and construction.

Developing execution and contracting strategies to effectively meet objectives.

Oversee Change Management process and providing cost and schedule control.

Compliance with all Company’s policies, procedures and technical standards.

Completeness of the basic engineering and look for opportunities for value addition .

Development of the PFD and input to the P&ID.

Detailed design of Proprietary technology, such as distillation columns, adsorption systems and heat exchangers .

Specifying of specifications for process and related equipment, line sizes, instruments and valves,

Applying engineering standards, procedures and support & guide to engineers .

Liaised with other engineering disciplines, Coordinated the Hazop, Performance testing and assessment teams.

Chalked out plan for trouble shooting, Workload planning, Performance review, mentoring of young engineers.

Project implemented : Petro chemical, Distillation columns, API bulk drugs, Polymers, Acrylic fibers, Distilleries, Biogas Plant, Acetaldehydes, CO2 plant, Synthetic Adhesives, Resins units, Ethyl acetate, Butyl acetate Sulphuric acid, Phosphatic fertilizer plant, DM water plant, ETP and various off sites like Alcohol storage tanks,tank farms, EPC etc.

II. Production Core Experiences:

Coordinates with marketing, planning and procurement functions for establishing production and delivery schedules with overall responsibility.

Preparing plant operating and revenue budgets and obtains approvals.

Ensuring that the operating costs remain within approved budgets by standardized production plan and capacity.

Preparing and submitting monthly budget compliance reports and variance reports.

Ensures that plant preventive maintenance schedules and optimal uptime of plant and machinery.

Monitoring plant performance on a daily basis.

Ensuring that the ERP package is constantly updated pertaining to manufacturing.

Coordinated plan and supported for new product development with the business development division.

Ensuring timely delivery of materials, routine maintenance, calibration and trouble shooting on a regular basis.

Reviewing new process and product technologies from R&D and providing the infrastructure required for scale-up and manufacturing.

Cost Management: Ensuring departmental budget for the financial year and constantly working on parameters for reduction in costs without compromising on Quality.

Resource Management: Ensuring optimum utilization of resources like manpower, equipments and materials with structured MIS system.

Developing employees on functional, technical skills/, safety etc.

Administering control measures of the resources and facilities.

Audits: Implementing the ISO, EMS and OHSAS in production department by conducting the approval audit.

Documentation: Ensuring programming, planning, executing raw materials, production and delivery activities with proper documentation.

Co-ordination: Reviewing inters department compliance, SOPs, equipment, process and co ordinate GMP, ISO, QA, QC, Stores, Regulatory Affairs, Purchase and HR with regards to production.

Safety Health Environment: Responsible for the overall SHE Activities and ensures compliance under the Act.

Drives and coordinates all activities for certification of ISO, EMS, OSHAS, and WHO etc.

Ensuring safety is maintained at all levels at all times.

B. Business Acumen: Setting-up production targets to meet time schedule, cost and quality parameters.

C. Strategic Thinking & Planning: Formulating and implementing strategies for achieving annual business goals and managing overall operations of the unit. Foresee the performance bottleneck, corrective measures to lead the team to achieve organizational goals and industry best practices.

D. Statutory Compliance: Ensuring compliance with the provisions of the following statutes:

The Factory's Act and state Factory Rules and all applicable statutory rules and regulations related with the Operations of factory.

Compliances of EHS regulations: Possessing experience with state PCB, CPCB and Govt. bodies.

Liaison work. : Knowledge of rules for storage of all materials including Explosives Rules etc.

Knowledge of Central Excise Rules & Procedures prohibition& Excise regulation for storage of alcohol.

E. People Management: Monitoring performance of individuals on functions & behavior, and filling the gaps.

Develops procedures and policies to increase productivity, teamwork and quality focus.

F. Leadership: Ensuring qualified successors are available for key positions.

G. Customer Focus: Supporting the Marketing team for timely dispatch of the quality product.

H. Vendors: Ensuring use of quality material and approved quality vendors.

III Achievements :

Enhanced productivity to targeted level which was pending from long years by process optimization,

specific direction at TEAMEC Chlorates Limited .

Implemented 2 nd Line of Acrylic fibers manufacturing unit consisting of 6 reactors of 50 k l each with distillation unit, spinning line etc. at M/s Pasupati Acrylone Limited Moradabad which was difficult from many years.

Savings achieved due to reduction of raw materials consumptions,utilities and power consumptions by INR 3 crores in a year by implementing Continuous Improvement Plan.

Enhanced existing Acrylic fiber plant capacity from 100 TPD to 140 TPD .

Credit to implement green field projects of Acetaldehyde, Acetic Acid, Ethyl Acetate, Butyl Acetate in 4 months time .

Implemented API Bulk drug GMP project in 6 months time with 36 reactors in M/s Surya Pharmaceuticals Limited Chandigarh .

Renovated old API Unit consisting of 34 Reactors and distillation systems in house in 4 months m/s Tata Projects / Jacob Engineering were asking 15 months time for the same rennovation.

Independently executed green field Polymer Projects of M/s Kores India Limited at Rudrapur in 8 months time and brought the unit in profitability in the very beginning years.

Raised the productivity in M/s PPCL and awarded with promotion in two years.

Played a very vital role in raising the Production of the unit and got awarded by Unit Head on regular basis .

Professional Experience

Professional Experience : 14 Years as Unit Head on all over India basis

Currently Technical Adviser Consultant Self Employed : Speciality Chemical Products and industries .

Manufacturing, Process Engineering, Projects, Operations Management, GMP, Re engineering, Capacity Enhancement, Process Optimization s, Debottle necking, System Anaysis,Overall business enhancement of Company, Business Development, Business Planning, Turn around, Budgets, Quality Control, Six Sigma, Lean Manufacturing, Business Strategy, Technology Transfer, Troubleshooting, Process Design, New products Development, Marketing, Commercial inputs, Strategic Planning, Strategy, Profitability .

Sr. G M Oprn. & Unit Head: M /s TEAMEC Chlorates Limited (M/s Chemfab Alkalies Group ) Ongole – since Jan . 2015 to October 2015 Sp. Chemicals .

Unit Head TEAMEC Chlorates Limited, A unit of Chemfab Alkalies Limited Chennai with Single point accountability of Operation of Continuous Process DCS based Sodium Chlorate Chemical / Fine Chemicals unit . Responsible for P & L of Unit. Group - Dr. Rao’s Holdings, TEAM group Chennai ( B to B business ). The Company is diversified in business of Engineering, manufacturing of Fine Chemicals & Chlor Alkalies chemicals . Group Turn over INR 1000 Crores. & Group manpower 1200.

Unit Head M/s PUNJ LLOYD Delhi / Indore Since Feb .2013 to Dec. 2014.

Management Functional Unit Head with Single point accountability of operation of continuous process Super Ceramic Fibre unit to cater requirement of various types of hot insulations and Poly Urathine PUF based manufacturing units to cater requirement of various cold houses and PUF pannels with all operational functions in Integrated Management system with SAP System working . Responsible for P & L. Group Turn over INR 3000 crores & Group manpower 20000 . ( B to B business )

Head Chemical Division M/s Pasupati Acrylon Limited, Moradabad U.P. Since May2011 to January 2013 Functions : Head Production & Projects

Managing overall production of 140 TPD Acrylic fiber Plant as Department Head -- PLC, DCS, SCADA based Process control system of Continuous Polymerizations with CSTRs, Distillation units, Acrylic Fiber spinning unit / Dyed acrylic fiber unit (SNIA BPD Technology). Commissioned new projects . Enhanced existing Acrylic fiber plant capacity from 100 TPD to 140 TPD .Unit turn over INR 600 crores. Manpower 750 . ( B to B business )

Sr. General Manager (Works ) Unit Head / Project Head API Bulk Drug Plant, M/s Surya pharmaceutical ltd, Chandigarh & Sambha since Feb . 2008 to April 2011 Functions : Operations & Projects

Headed and Provided a single point accountability of Greenfield projects and Brown field Projects of 7 ACCA, 7 ANCA, Cefixime, Cephalexin, Cefuroxime, Cefaclor, Menthol with GMP standards to deliver the projects in accordance with commitments with full project authority, within established budget in company’s operating policies to manage and direct assigned project resources. Commissioned Plants with modernized facilities of global standard. Assisted manufacturing operations, coordinated plant activities to set up standards with accountability for strategic utilization & deployment of available resources to achieve organizational objectives. Turn over INR 1400 crores & manpower 750. ( B to B business ).

General Manager ( Works ) Unit Head M/s Kores India Ltd., Mumbai : Unit : Rudrapur

Oct. 2004 To Jany20 08 Functions : Operations & Projects

Headed independently with power of attorney a green field Polymer Project from conceptual stage to manufacture Polymers, Synthetic Resin Adhesives, Polymers of vinyl acetate, Polymers of Acrylates, Synthetic Rubber based Adhesives, and Various others . Implemented Project with in 8 months time and finally headed Production Unit . Group turn over INR 1000 crores & Unit manpower 450 . ( B to C business) .

General Manager ( Works ) Unit Head – Century Group Vapi Gujarat : November 2000 to September 2004 Functions : Operations & Projects Similar Functions as of M/s Kores India Ltd .

Brought the Business from debt to profit in very first year itself. The company got recognition in the market and it became leader in the field. Group Company turn over INR 1000 crores & Unit manpower 250 (B to C business).

Project / Production Manager/ Project Head M/s Jubilant Life Science Ltd.) U. P. / Nira Pune Maharastra: May 1995 To October 2000 Functions : Operations & Projects

Single point accountability as Project Manager of Continuous process Organic Chemicals Projects with Project conceptualization, PFD development, designing, Contract finalization, Ordering, Dealing with Process Licensers, Suppliers, Site Fabricators and Contractors, Planning, scheduling, Procurement of materials & Equipments, construction . Up-gradation of Plants, Development and Design of new project, Bill of materials preparations, Vendors development, Execution, commissioning . Group turn over INR 5000 crores & Unit manpower 750 ( B to B business) .

Dy. Manager Chemicals / Plant Manager M/s PPCL New Delhi (A Govt. of India U. T ) : August 1987 to 15 th May 1995 Functions : Operations & Projects

Functional Plant manager with Active participation with Process Licensers GmbH Lurgi West Germany and Reputed Engineering Company M/s FEDO, PDIL, DMCC, and various others . Erected, Commissioned and operated fertilizer plant, DM Water plant, water treatment, Effluent treatment plant & Roaster and Acid unit by GmbH Lurgi West Germany . Taken charge of Production, Operations and maintenance of Roaster and Acid plant, SSP plant . Company turn over INR 400 crores & Unit manpower 750 ( B to B business).

Personal Information

Name : Om Prakash Mahto

F’ Name : Late Nathu Singh

DOB : 12.01.1961

Address : Ansal Courtyard Shastri Puram Agra U.P. 282007

Educational Qualification

B.E. (Chemical Engineering) – 1st Class passed in June 1984 from IIT Roorkee.

M. Tech (Chemical Engineering)- 1st Class passed in Dec.1985-IIT Kharagpur

Training Undergon

ISO 9000, 14000, 18000

Primavera Software of Project Managements

Safety Management & Hazardous Control in Chemical Industry NITIE, Mumbai. Certificate course

Environmental Mangement ISM Dhanbad. Certificate course

SAP/ ERP

Computer Skills

WINDOWS based application/ MS Office, SAP etc.

Strengths

Administrative skill, team work, Personal integrity, Proactive to drive business agenda, Ability to challenge status quo. Excellent communication with written and verbal, dedicated analytical ability, honesty, self confidence, Achievement oriented, problem solving, coordination and analysis, ability to motivate people,

Expected Salary : Open for Negotiation / As per standard of Company

Notice Period : N A

Current Location : NCR Delhi

Preferred location : Any where in INDIA

Total Experience 29 years

Above in formations are true to the best of my knowledge. My social profile is available on linkedin as om prakash Technical Advisor speciality chemicals .

(Om Prakash Mahto )

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